Stone slab production methods and systems

ABSTRACT

This document describes systems and processes of manufacturing, visualizing, and distributing stone slabs. In an exemplary embodiment, a 3D scene may be generated that depicts a portion of a major surface of a stone slab at a target area of a slab installation environment.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application and claims priority toU.S. application Ser. No. 16/671,924 filed on Nov. 1, 2019, which is acontinuation application of and claims priority to U.S. application Ser.No. 15/478,008, filed on Apr. 3, 2017.

TECHNICAL FIELD

This document describes processes and systems for manufacturing,visualizing, and distributing building materials in conjunction with,for example, a digital image representation of the building material.

BACKGROUND

Stone slabs are a commonly used building material. Granite, marble,soapstone, and other quarried stones are often selected for use ascountertops, tables and floors. Stone slabs may also be formed from acombination of natural and other materials that can provide improvedqualities such as aesthetic characteristics, reproducibility, andstain-resistant or heat-resistant properties. Stone slabs are typicallycut to a desired size and shape prior to installation.

Digital representations of stone slabs may be used to facilitate orautomate slab selection and cutting. For example, digitalrepresentations of stone slabs have been used to facilitate selection ofstone slab styles, colors, etc. by a customer, such as by viewing adigital representation of a stone slab style.

SUMMARY

Some embodiments described herein include systems and methods ofmanufacturing, distributing, and/or visualizing surfaces, such as stoneslab surface (e.g. quarried stone slabs, processed stone slabs, tiles,such as porcelain or ceramic tiles, partial stone slabs, etc.), wallcoverings, paneling, flooring, veneers, architectural finishes, buildingmaterial surfaces, and other surfaces. For example, building materialsmay include stone slabs suitable for use in living or working spaces(e.g., along a countertop, table, floor, reception area, or the like).Exemplary systems and methods may include generating an image andmetadata related to a surface (e.g. building material surface) that canbe used in subsequent visualization, fabrication, installation, qualityassurance, or other activities. The image and associated metadata mayfacilitate realistic visualization of a particular building materialwithout requiring significant physical manipulation, thereby improvingselection, fabrication, and installation processes. Alternatively oradditionally, some embodiments described herein improve performance andspeed of a visualization system, while reducing the processing burden ofserver and client applications and/or latency time in communicationsbetween server and client applications.

Particular embodiments described herein include a system for producingstone slabs. The system includes a production database stored at aserver system and including slab image files corresponding to a physicalinventory of stone slabs. Optionally, each slab file may be associatedwith only a single stone slab in the physical inventory and include animage of a major surface of the single stone slab. The server systemincludes software programmed to receive a slab image file from theproduction database and an environment image of a slab installationenvironment. Optionally, the server system is further programmed todetermine a geometry of a target area of the slab installationenvironment, and generate a scene depicting at least a portion of themajor surface of the stone slab associated with the slab image file atthe target area in the slab installation environment. The server systemoptionally includes a network communication device to transfer the sceneto a client application for display of the scene at a client device. Thetarget area may have a different geometry than the major surface of thestone slab.

In some implementations, the system can optionally include one or moreof the following features. Each slab image file may graphicallyrepresent a major surface of a corresponding stone slab in the inventoryof stone slabs, and each slab image file may include image metadataincluding an identifier that uniquely identifies the corresponding stoneslab, and at least one dimensional characteristic of the correspondingstone slab. The image of the major surface of the single stone slab mayhave an image length and an image width, the single stone slab may havea stone slab length and a stone slab width, and the dimensionalcharacteristic stored as image metadata may include a numeric ratio ofthe stone slab length to the image length (L_(slab)/L_(image)). The 3Dscene may include all or one or more portions of the major surface ofthe stone slab without repeating any portion of the major surface of thestone slab. The slab image file may be generated at a stone slabmanufacturing site. The client application may be configured to receiveuser inputs to customize characteristics of the stone slab in the 3Dscene. The customized characteristics may be selected from the groupconsisting of edge style, stone slab orientation, and stone slabposition. The inventory of stone slabs may include processed stoneslabs. The processed stone slabs may include predominantly quartz. Theinventory of stone slabs may include quarried stone slabs.

Some embodiments described herein include a method for producing stoneslabs, including storing slab image files at a production database of aserver system, the slab image files corresponding to a physicalinventory of stone slabs, each slab image file associated with only asingle stone slab in the physical inventory and including an image of amajor surface of the single stone slab, receiving a slab image file fromthe production database and an environment image of a slab installationenvironment, determining a geometry of a target area of the slabinstallation environment, generating a 3D scene depicting at least aportion of the major surface of the stone slab associated with the slabimage file at the target area in the slab installation environment, andtransferring the 3D scene to a client application for display of the 3Dscene at a client device. The target area may have a different geometrythan the major surface of the stone slab.

In some implementations, the method can optionally include one or moreof the following features. Each slab image file may graphicallyrepresent a major surface of a corresponding stone slab in the inventoryof stone slabs, each slab image file may include image metadataincluding an identifier that uniquely identifies the corresponding stoneslab, and at least one dimensional characteristic of the correspondingstone slab. The image of the major surface of the single stone slab mayhave an image length and an image width, the single stone slab may havea stone slab length and a stone slab width, and the dimensionalcharacteristic stored as image metadata may include a numeric ratio ofthe stone slab length to the image length (L_(slab)/L_(image)). The 3Dscene may include all or one or more portions of the major surface ofthe stone slab without repeating any portion of the major surface of thestone slab. The slab image files may be generated at a stone slabmanufacturing site. The client application may be configured to receiveuser inputs to customize characteristics of the stone slab in the 3Dscene. The customized characteristics may be selected from the groupconsisting of edge style, stone slab orientation, and stone slabposition. The inventory of stone slabs may include processed stoneslabs. The inventory of stone slabs may include quarried stone slabs.

Some embodiments described herein include a method for producing stoneslabs, including receiving a slab image file and an environment image ofa slab installation environment, generating a 3D scene depicting atleast a portion of the major surface of the stone slab associated withthe slab image file at the target area in the slab installationenvironment, and transferring the 3D scene to a client application fordisplay of the 3D scene at a client device.

The systems and techniques described herein may provide one or more ofthe following advantages. First, some embodiments described hereininclude a system that can reduce costs and improve efficiency associatedwith generating and displaying a visualization, such as visualization toassist a user selecting between various stone slabs. Alternatively oradditionally, some embodiments can reduce costs and improve efficiencyin quality control, distribution, fabrication/stone cutting, and otherprocesses. Optionally, the system can generate and store digital imagesalong with a set of additionally useful data as stone slabs or othermaterials move through an existing manufacturing line without asignificant impact on the equipment and handling of the stone slabs orother materials. In another example, the system can generate and storedigital images for subsequent use in visualization, quality controlactivities, matching or grouping of multiple stone slabs or othermaterials for shipment and/or use together, nesting or layout designactivities by a fabricator, and/or other activities throughout the lifeof the stone slab or other materials.

Second, in some embodiments described herein, a particular stone slab orother material and a corresponding image (optionally, with embeddedmetadata for the particular slab or other material) may improveselection and/or purchasing processes by providing a realisticvisualization consistent with the appearance of the associated stoneslab or other material when installed in an installation environment.For example, a visualization process depicting a stone slab in a slabinstallation environment improves the customer selection process byfacilitating visualization of a stone slab in an actual installationenvironment (e.g. such as the environment where the stone slab is to beinstalled instead of a showroom). Alternatively or additionally, avisualization including specific stone slab(s) available for purchasemay facilitate visualization of a specific stone slab so that thecustomer can visualize the appearance of the actual physical stonebefore it is delivered or installed in the installation environment.Accordingly, in some embodiments, visualizations described herein mayimprove the overall customer satisfaction with the selection process andthe final stone slab or other material installed in the installationenvironment.

Third, some embodiments described herein may facilitate visualization ofhow different design elements of an installation environment appeartogether (e.g. in combination in a single installation environment). Forexample, various surfaces or features of an installation environment maybe visualized together to facilitate selection of a surface or feature,such as a stone slab, that is suitable for use in the installationenvironment with one or more other surfaces or features. One or moreelements may be efficiently modified or changed to quickly arrive at aselected combination of surfaces and features or an installationenvironment. In some embodiments, visualizations described herein mayfacilitate a shortened timeframe for a user to select one or moresurfaces, features, or combinations thereof.

Fourth, in some embodiments described herein, a processing burdenassociated with generating and displaying a visualization depicting astone slab may be reduced. For example, a server system may beconfigured and programmed to perform much or all processing so as toreduce the processing burden on a client device. Alternatively oradditionally, in some embodiments, communication speed between a serverand client application may be increased, and latency time reduced, suchthat communication reliability and/or a user experience is improved.

Fifth, in some embodiments described herein, multiple operations relatedto stone slab manufacturing, distribution, and/or production may beeliminated or performed in parallel, reducing the complexity ofdelivering and installing a stone slab in an installation environment.For example, in some embodiments, a stone slab fabrication or nestingoperation, including steps of measuring an installation environment andgenerating a slab layout to fit the installation environment, may beperformed at least partially together with steps related to avisualization operation. Generating a scene depicting a particular stoneslab in the installation environment may include steps of creating alayout of slab portions in the installation environment that has a highlevel of dimensional accuracy such that the layout can be used whencutting the physical stone slab for installation. The resulting layoutcan thus be used in both visualization operations and in subsequentnesting operations of the physical stone slab.

Sixth, in some embodiments described herein, generating a 3D scenedepicting at least a portion of a stone slab in a slab installationenvironment allows a user to view multiple stone slabs in rapidsuccession without manipulation of a physical stone slab. A user maymanipulate the visualization to view (e.g. in real-time) a variety ofstone slab styles, specific stone slabs, layouts/orientations for slabs,colors, edge profiles, etc., while reducing physical manipulation ofphysical stone slabs, stone slab samples, or paper representations thatmay require additional physical manipulation and additional time and/orcost to generate. In some exemplary embodiments described herein, a usermay view multiple stone slabs in rapid succession that have the samestyle, color type, edge profile, etc., in order to select a particularstone slab from an inventory of stone slabs having similarcharacteristics.

Seventh, in some embodiments, generating a scene depicting at least aportion of a stone slab in a slab installation environment mayfacilitate accurate cost quoting. The dimensionally accurate layout, andset of stone slab characteristics identified in a visualizationoperation (e.g. edge profile), facilitates calculation of an accuratecost quote. In some embodiments, a quote may be generated that isassociated with a particular stone slab stored in inventory (e.g. ratherthan related generally to a stone slab style), further enhancing thereliability of the cost quote.

Eighth, in some embodiments, a precise dimensional relationship betweena stone slab and an associated image can facilitate reliablevisualization and nesting operations and may reduce manual measurementor other manipulation of the physical stone slab. Multiplevisualization, nesting and cutting operations of a single slab may becarried out using a single image (e.g. generated at a time ofmanufacture), providing benefits in inventory management and otheroperations even after a portion of the stone slab has been cut orremoved for a particular project. The image may be used to identify ormatch the remaining slab portion without requiring physical handling oradditional imaging of the remaining slab portion.

Ninth, some embodiments described herein include a system that generatesimage metadata associated with a stone slab that provides informationwhich may optionally allow an inventory of numerous stone slabs to bereadily searched and cataloged without physically handling or moving theactual stone slabs. Additionally, one or more image characteristicsstored as part of the image metadata may be used to group stone slabsfor a particular customer or project, or to identify a particular slabfrom an inventory of stone slabs for a particular customer or project.Accordingly, a database including slab image files associated with aphysical inventory of stone slabs facilitates automation of such tasksand enhances reliability in matching and selecting of a stone slabhaving desired characteristics, such as in selecting a particular stoneslab for use in generating a visualization of the stone slab in aninstallation environment.

The details of one or more implementations are set forth in theaccompanying drawings and the description below. Other features andadvantages will be apparent from the description and drawings, and fromthe claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is a diagram of an exemplary system used in manufacturing,visualizing, and distributing a stone slab in conjunction with, forexample, a digital image representation of the stone slab.

FIG. 2 shows a user interface of a client application.

FIG. 3 shows another view of the user interface of the clientapplication of FIG. 2.

FIG. 4 shows another view of the user interface of the clientapplication of FIG. 2.

FIG. 5 is a diagram of an exemplary system used in manufacturing,visualizing, and distributing a stone slab in conjunction with, forexample, a digital image representation of the stone slab.

FIG. 6 is a flow diagram of an exemplary process of manufacturing stoneslabs and generating image files of the slabs.

FIG. 7 is a diagram of an exemplary stone slab and associated imagefile.

FIG. 8 is a flow diagram of an exemplary process of manufacturing,visualizing, and distributing stone slabs.

FIG. 9 is a flow diagram of an exemplary process of generating avisualization of a stone slab in an installation environment.

FIG. 10 flow diagram of an exemplary process 908 of generating a sceneof a stone slab visualization.

FIG. 11 shows an environment image of an installation environment.

FIG. 12 shows a plan view of major surfaces of an exemplary slab imagedivided into slab image portions.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Referring to FIG. 1, an exemplary stone slab post-production system 10is shown that can be used to facilitate various operations related to aphysical inventory of stone slabs 50. System 10 includes a server system11, production database 30, and client device 60 that are incommunication with one another to exchange information related to thephysical inventory of stone slabs 50, stone slabs 50, and/or aninstallation environment where one or more stone slabs 50 a, 50 b, 50 c(e.g. stone slabs or portions of stone slabs) of the physical inventoryof stone slabs 50 may be installed. Server system 11 and/or clientdevice 60 includes software programmed to generate a scene depicting atleast a portion of a stone slab from the physical inventory of stoneslabs 50. In some embodiments, server system 11 may be configured toreceive an environment image of a slab installation environment (e.g.from client device 60) and generate a scene depicting at least a portionof the stone slab in the slab installation environment. Accordingly,some embodiments of system 10 facilitate visualization of a stone slab,available in a physical inventory of stone slabs 50, in a slabinstallation environment. System 15 and/or client device 60 can generatea realistic visualization of one or more physical stone slabs 50 a, 50b, 50 c that facilitates customer selection, cost quoting, and/orsubsequent fabrication operations, such as fabrication and/orinstallation of countertops, floors, work surfaces, etc.

Production database 30 stores information related to system 10,including slab image files 20 associated with physical stone slabs 50 a,50 b, 50 c in the physical inventory of stone slabs 50. Productiondatabase 30 may include a data storage system made up of one or morerepositories that store information related to system 10, and/or thatmay be stored at server system 11. Production database 30 may includeone or more local databases, for example housed locally at amanufacturing location, and/or may include one or more remote databases.In an exemplary embodiment, production database 30 includes acloud-based system that may be accessed remotely, and access to variouscomponents of production database 30 may be selectively granted toparticular users. A manufacturer and/or system administrator may havecomplete access to all aspects of production database 30, while a remoteparty may be granted access only to particular content, such asparticular slab image files 20 that a remote party has purchased or isconsidering purchasing, for example.

In addition to slab image files 20, production database 30 may storeother stone slab information 32 and/or distribution information 33. Suchinformation may similarly be used for one or more operations related tostone slabs 50 and/or selectively distributed to one or more users.

Slab image files 20 may be generated at an image generator station 15.Image generator station 15 may operate to generate slab images at alocation where stone slabs 50 are manufactured and/or stored. Forexample, image generator station 15 may generate slab images as part ofan existing manufacturing line, such as after a polishing operation of aslab manufacturing line. Alternatively, image generator station 15 mayoperate to generate slab images at a location remote from an initialmanufacturing location. For example, image generator station 15 maygenerate slab images as part at a fabrication location, such as alocation where stone slabs are cut for installation in a desiredapplication, (e.g. after being shipped from a location of initialmanufacture), or at a distribution center or warehouse (e.g. after beingshipped from a location of initial manufacture).

In an exemplary embodiment, slab image files 20 include a digital image21 of an associated stone slab, and/or information related to the stoneslab stored as image metadata 25, such as a unique identifier,manufacturing location and/or date/time, dimensional relationship(s),thickness, gloss readings, color characteristics, purchaser information,processing conditions, genealogy, etc. Some data, such as the uniqueidentifier, manufacturing location and/or date/time, dimensionalrelationship(s), thickness, gloss readings, color characteristics, etc.may be stored as read-only data. Other information, such as a purchaserinformation and/or other information may be readily updateablethroughout the life of slab image file 20, and may be selectable suchthat certain metadata may be included and/or viewable only by aparticular user.

Server system 11 includes software programmed to perform various tasksassociated with the physical inventory of stone slabs 50. Server system11 may include software programmed to receive and manipulate slab imagefiles 20 and/or slab environment images (e.g. captured and/or receivedfrom client device 60), and/or combine at least some aspects of theimages to generate a scene depicting a slab in an installationenvironment. Server system 11 includes one or more network communicationdevices 17 that provide communication between production database 30and/or client device 60, and facilitate transfer of slab image files 20,slab environment images, and/or other data.

Client device 60 includes a user interface display 61, networkcommunication device 62, one or more inputs 63 for user commands, and aclient application. Client device 60 is a device configured to receiveinformation related to one or more stone slabs in the physical inventoryof stone slabs 50 from server system 11. In various exemplaryembodiments, client device 60 may be a consumer device, such as aconsumer computing device, and/or may include a smartphone, personaldigital assistance, tablet computing device, laptop computing device,desktop computing device, or the like. User interface display 61 maydeliver visual output to a user related to the physical inventory ofstone slabs 50, such as a scene depicting a stone slab in aninstallation environment. In various exemplary embodiments, userinterface display 61 may include a touch screen, projector, virtualreality simulator, 3D display, or the like. Network communication device62 facilitates transfer of data to and from server system 11, such as acellular, WLAN, short-wavelength UHF, or optical communication device,or the like. In an exemplary embodiment, client device 60 includes acamera or image capturing device 65 configured to capture a digitalrepresentation of a slab installation environment. Image capturingdevice 65 may be an integral component of client device 60, such as arear-facing camera. Alternatively or additionally, image capturingdevice 65 may be removably attachable with other portions of clientdevice 60, and/or separate from other portions of client device 60 (e.g.such that images captured by image capturing device 65 are subsequentlytransmitted to client device 60). In various embodiments, imagecapturing device 65 may include a visible light camera, infrared camera3D scanning device, time-of-flight camera, structured light scanner,stereoscopic scanner, and the like. Alternately or in addition,pre-loaded images of installation environments may be selected and usedin a visualization operation.

Server system 11 may be configured to depict a stone slab from thephysical inventory of stone slabs 50 in a slab installation environment.In an exemplary embodiment, server system 11 is programmed to receive aslab image file 20, including a slab image 21 and slab image metadata 25associated with a particular stone slab in the physical inventory ofstone slabs 50, and/or an environment image of a slab installationenvironment. The slab image file and/or environment image may bereceived from production database 30 stored at server system 11, aremote production database 30, client device 60, or another repositoryof slab image files or environment images. In some embodiments, a usermay transmit one or more environment images of the installationenvironment from client device 60 (e.g. by capturing an environmentdevice via image capturing device 65 and transmitting the image fromclient device 60 to server system 11).

Server system 11 and/or client device 60 may include software programmedto identify geometry of a target area of the slab installationenvironment where portions of the slab may be installed, andsubsequently divide the slab image into slab image portions fitted tothe target area. The slab image portions may be combined with theenvironment image at the target areas to generate a scene depicting theslab image portions in the installation environment. The generated scenemay then be displayed by a client application of client device 60. Invarious exemplary embodiments, the generated scene may be a 2D scene, 3Dscene, or virtual reality environment that provides a visualization ofone or more surfaces of an installation environment. In this way, system10 can provide accurate and efficient visualizations of a stone slab inan installation environment that facilitates purchasing decisions, costquoting, and/or subsequent fabrication operations of the physical stoneslab (e.g. mapping and cutting the physical stone slab forinstallation).

In various exemplary embodiments, software programmed to perform varioustasks associated with the physical inventory of stone slabs 50,visualization of an installation environment, and other tasks, may beperformed anywhere on system 10. For example, software programmed toreceived and manipulate slab image files 20 and/or slab environmentimages, and/or combine at least some aspects of the images to generate ascene depicting a slab in an installation environment, may be stored andexecuted on server system 11, client device 60, and/or other componentof system 10. Alternatively or additionally, software programmed todepict a stone slab from the inventory of stone slabs 50 in aninstallation environment, identify geometry of a target area of aninstallation environment where portions of the slab may be installed,and/or divide the slab image into slab image portions fitted to thetarget area, may be stored and executed on server system 11, clientdevice 60, and/or other component of system 10.

The inventory of stone slabs 50 may include one or more types of stoneslabs, including quarried stone slabs, processed stone slabs, tiles,such as porcelain or ceramic tiles, partial stone slabs, and the like.In various embodiments, stone slabs 50 may be suitable for installationat one or more surfaces or locations of an installation environment,including as a countertop, backsplash, flooring, wall covering, cabinetfacing, veneer, pillar, fireplace surround, or other surfaces of aninstallation environment. Alternatively or additionally, system 10 canbe used to facilitate various operations related to a physical inventoryof any building materials or surfaces, such as countertops,backsplashes, flooring, wall coverings, cabinet facings, veneers,pillars, fireplace surrounds, or other surfaces.

Referring to FIGS. 2-4, a user interface 280 of a client application isshown, including a 3D scene 285 generated by system 10 that depicts atleast portions of a stone slab 221 a, 221 b, 221 c in an installationenvironment, and a menu 286 including one or more options for a user tomodify 3D scene 285. The generated scene may depict at least portions ofsurface, such as a major surface of a physical stone slab, available inan inventory of surfaces, such as an inventory of physical stone slabs.User interface 380 allows a user to visualize a specific stone slab orother material that may be installed in the installation environment,and to customize or modify the 3D scene to quickly visualize multipleconfigurations while reducing physical manipulation of the associatedstone slab.

In an exemplary embodiment, the client application may be initializedupon receiving a user initialization input. The client application maythen provide a series of user prompts that request information relatedto generation of a 3D scene. For example, client application may prompta user to select a slab installation environment from a repository ofslab installation environments, including a slab installationenvironment captured by the user (e.g. the user's kitchen, bathroom,workspace, etc. where a stone slab may be installed), or a preloadedslab installation environment. In some embodiments, client applicationmay request that the user select from one or more slab installationenvironment styles in order to select a preloaded slab installationenvironment, such as a “modern,” “transitional,” or “traditional” style.Upon receiving an input, the client application may output a 3D sceneincluding the selected slab installation environment.

Referring to FIG. 2, 3D scene 285 displayed by client interface 280 isshown, depicting countertop portions 221 a, 221 b, 221 c. User interfacemenu 286 includes inputs for a user to customize or modify theappearance of 3D scene 285. In an exemplary embodiment, user interfacemenu 286 includes a plurality of stone slab styles (e.g. “Style A,”“Style B,” “Style C,” etc.) that a user may select to include in theinstallation environment. To insert a desired slab style into 3D scene285, a user may select a desired target area 271 a, 271 b, and/or 271 c,followed by the desired stone slab style, or vice versa. Clientinterface 280 thus can display a 3D scene incorporating more than oneslab style in different target areas 271 a, 271 b, 271 c.

In some exemplary embodiments, user interface menu 286 may includeinputs for a user to customize the appearance of one or more featuresand/or architectural details of 3D scene 285. For example, lighting 281,shelving 282, cabinetry 283, and/or other aspects of installationenvironment 285 (e.g. flooring, wall coverings, fixtures, appliances,etc.) may be selectable by a user to generate a customized visualizationof installation environment 285.

User interface menu 285 includes inputs to toggle between predeterminedviewing angles or vantage points 287, such as, in some embodiments, a)higher-left b) lower-right, c) close-up edge, and/or d) top-down vantagepoints. Alternatively or additionally, a viewing angle of 3D scene maybe manipulated by clicking or pressing on the 3D scene and dragging to aselected viewing angle.

User interface menu 286 may include features that facilitate efficientand intuitive modification of 3D scene 285. In an exemplary embodiment,client interface 280 includes a stone slab design slider 288. Stone slabdesign slider 288 is configured to receive input from a user to quicklyscroll between a plurality of stone slab designs arranged, for example,from light to dark colors and/or by tone or other attributes.Manipulation of stone slab design slider 288 allows client interface 280to quickly receive inputs to configure 3D scene 285 with stone slabshaving similar designs.

In various exemplary embodiments, each stone slab selectable via stoneslab design slider 288 may be preloaded by the client application toreduce latency time between user input selection and the correspondingdisplay in the 3D scene. For example, client application may beconfigured to display each stone slab selectable via stone slab designslider 288 even during periods in which communication is not availablebetween client device 60 and server system 11, for example.Alternatively or additionally, the client application may communicate aselected stone slab style to server system 11, and receive from serversystem 11 an updated 3D scene for display by client interface 280.Processing the 3D scene at server system 15 may reduce the processingburden required to operate the client application.

User interface menu 286 may include one or more icons to toggle betweenvarious menus, including an environment image menu, edge profile menu,stone slab information menu, comparison view etc. A user may thusnavigate through a series of menus and options to modify the 3D scene.

Referring to FIG. 3, user interface 280 of a client application isshown, providing a comparison view in which different stone slabs aredepicted at a particular target area 271. For example, user interface280 facilitates rapid, side-by-side visualization of different stoneslabs by a comparison slider 287 movable across the installationenvironment. Movement of comparison slider 287 in direction ‘A’ (e.g. tothe left in the view of FIG. 3) increases the portion of the scene inwhich “Style F” is depicted in the target areas, and movement of slider287 in direction ‘B’ (e.g. to the right in the view of FIG. 3) increasesthe portion of the scene in which “Style E” is depicted in the targetareas. Alternatively or additionally, the comparison view maysimultaneously display stone slabs having the same style that correspondto different physical stone slabs in a physical inventory of stoneslabs. The comparison view may thus facilitate selection of a specificphysical stone slab, in addition to selection of a stone slab style.

Referring to FIG. 4, user interface 280 of a client application isshown, providing a comparison view in which different edge profiles of astone slab are depicted. For example, user interface 280 facilitatesrapid, side-by-side visualization of different edge profiles of a stoneslab by a comparison slider 287 movable across the installationenvironment. Movement of comparison slider 287 in direction ‘A’ (e.g. tothe left in the view of FIG. 4) increases the portion of the scene inwhich a first edge profile is depicted in the target areas, and movementof slider 287 in direction ‘B’ (e.g. to the right in the view of FIG. 4)increases the portion of the scene in which a second edge profile isdepicted in the target areas. The comparison view may thus facilitateselection of a specific stone slab features or customization options, inaddition to selection of a stone slab style.

In an exemplary embodiment, navigation through user interface 280generates a final installation configuration including a stone slab(e.g. associated with a physical stone slab in an inventory of stoneslabs), dimensions of a target area where the stone slab is to beinstalled, edge profile, and/or other characteristics that can be usedto generate a reliable and accurate cost quote. Server system 11 and/orthe client application of client device 60 may be programmed withsoftware that identifies a cost associated with each characteristic orcombination of characteristics of the installation environment. Thecosts may be complied to generate a cost quote in real-time that isdisplayed by client interface 280 while the 3D scene is generated and/ormodified. Alternatively or additionally, a cost quote may be generatedafter an input is received that confirms the final installationconfiguration.

In some embodiments, client application 280 is programmed with softwareconfigured to receive a purchase confirmation of the stone slab depictedin the 3D scene. A stone slab depicted in the 3D scene that isassociated with a physical stone slab available in inventory reducesintermediate steps of confirming availability of a stone slab (e.g. byphysically manipulating the inventory of stone slabs). System 10 maythus quickly confirm a purchase of a specific stone slab (e.g. in realtime). Client device 60 may communicate with server system 11 andproduction database 30 to assign the stone slab to the customer, such asby updating the metadata of the slab image file and/or otherwise makingthat particular stone slab unavailable to other purchasers to select. Insome exemplary embodiments, a stone slab selected for visualization on aparticular client device 60 may be made temporarily unavailable forselection and display on other client devices 60 (e.g. in order toprevent selection of the same stone slab on multiple client devicessimultaneously).

Referring to FIG. 5, an exemplary system 500 can be used to produceand/or manage an inventory of one or more stone slabs, such as stoneslab 50 a, and slab image files 120 associated with each stone slab. Insome embodiments, system 500 may be included as part of system 10,and/or image generator 515 and database 530 may have features similar toimage generator 15 and production database 30 described above. In thisembodiment, system 500 generates a high resolution image of stone slabs50 a such that the images are available for use in one or moresubsequent operations throughout the life of the stone slabs.

In an exemplary embodiment, system 500 includes a manufacturing line 510including one or more stations for manufacturing stone slab 50 a. Forexample, stone slab 50 a may be a processed stone slab (e.g. such as amolded stone slab) comprising a quartz material and/or other particulatemineral material that, when mixed with pigments and a resin binder andcompressed, provides a hardened slab product suitable for use in livingor working spaces (e.g., along a countertop, table, floor, or the like).Manufacturing stone slab 50 a may include steps of dispensing one ormore particulate mineral mixes in a mold, vibrating and/or compactingthe particulate mineral mixes, curing the compacted mix, polishing amajor surface, and/or other operations. In other exemplary embodiments,stone slab 50 a be may a quarried natural stone slab, and manufacturingline 510 may include one or more cutting, polishing and/or otheroperations that can be used to manufacture stone slab 50 a.

Stone slab 50 a may be processed and/or cut to have a length L and awidth W, as desired for a particular application. For example, stoneslab 50 a may be a relatively large slab that may be cut to specificshapes for use in living or working spaces (e.g., along a countertop,table, floor, or the like). In various exemplary embodiments, stone slab50 a is at least 3 feet wide by at least 6 feet long, for examplebetween about 3 feet and 18 feet wide and between about 6 feet and 24feet long, or between about 4.5 feet and 7 feet wide and between about10 feet and 12 feet long. In some exemplary embodiments, stone slab 50 ais about 7 feet wide by about 12 feet long. In other embodiments, stoneslab 50 a is about 4.5 feet wide (approximately 140 cm wide) by about 10feet long (approximately 310 cm long). In some exemplary embodiments,stone slab 50 a may have an aesthetic effect including veins 51 and 52that extend partly or fully across a complete length L of the stone slab50, through all or part of the thickness T of stone slab 50 a, and/orpositioned relative to one another based on a predetermined pattern.Such characteristics may provide a natural vein appearance even when theslab is cut and edged to specific shapes.

Stone slab 50 a may proceed to an image generator station 515 resultingin a high resolution slab image file 520 of stone slab 50 a. In anexemplary embodiment, the image generator station 515 includes a camera(e.g., optionally, a “medium format” camera) mounted within anenclosure. Stone slab 50 a may sequentially pass into the enclosure andwithin the field of view of the camera to be imaged.

In some exemplary embodiments, a slab image file 520 includes asubstantially distortion free image 521 and image metadata 525associated with image 521. In embodiments in which image generatorstation 515 includes a medium format camera, image 521 may be a mediumformat image. Also in this exemplary embodiment, the image generatorstation 515 is present at the same manufacturing location and/or processas an initial stone slab polishing station and/or other manufacturingsteps. In some embodiments, the image generator station 515 ispositioned after a polishing station in system 500 and prior to storingthe slab for an inventory or for distribution to an offsite location. Inthis way, the high resolution slab image file 520 provides an electronicimage 521 of stone slab 50 a at the time that stone slab 50 a ismanufactured. In such embodiments, additional manipulation or physicalmovement of stone slab 50 a can be reduced, and stone slab 50 a is ableto move through manufacturing line 510, including an image generatorstation 515, as part of a streamlined system 500. Image 521 and/or otherinformation provided by slab image file 520 may then be used tofacilitate and/or automate one or more inventory management,distribution, fabrication or other operations throughout the life ofstone slab 50 a. In other exemplary embodiments, the image generatorstation 515 is positioned at a location remote from the manufacturinglocation (e.g. such that stone slabs are shipped to a different locationbefore being imaged by image generator station 515). For example, imagegenerator station 515 may be at a warehouse, distribution center, orfabrication location where stone slabs are cut or otherwise processedfor installation at an end-use location.

In an exemplary embodiment, image 521 provides a high resolution imagethat allows humanly perceptible characteristics of a physical stone slab50 a to similarly be observed in image 521. In various exemplaryembodiments, image 521 may exhibit between about 25 megapixels and 500megapixels, 30 megapixels and 200 megapixels, or about 40 megapixels.Image 521 may thus be used in addition, and/or as a substitute, toviewing the physical stone slab 50 a. Slab image file 520 may beprovided as any file or file set including the image 521 and imagemetadata 525. (As used herein, the term “high resolution image” means adigital image of a slab having a resolution of 25 megapixels or greater.As described in more detail below, other (lower) types of resolution arealso contemplated in some embodiments described herein.)

System 500 further includes, in addition to or together with the imagegenerator station 515, a metadata generator station that generatesmetadata 525 associated with stone slab 50 a and/or one or more imagesof stone slab 50 a. For example, the metadata 525 may includeinformation related to stone slab 50 a and/or slab image file 520 andmay be generated before, after, during, or as part of, an imagegenerator station 515. In various exemplary embodiments, metadata 525may include information related to image 521 such as a unique identifierassociating slab image file 520 with a particular stone slab 50 a,manufacturing information such as a date, time and location ofmanufacture, characteristics of stone slab 50 a such as dimensionalinformation, weight, thickness, gloss measurement, roughnessmeasurement, materials, presence and/or location of imperfections, oneor more color characteristics, including a color characteristic that mayuniquely identify a particular stone slab 50 a, and/or a dimensionalrelationship between stone slab 50 a and the associated image, asdescribed in greater detail herein.

System 500 further includes one or more databases 530 storinginformation related to system 500. Slab image files 520 associated withstone slabs 50 a and generated at an image generator station may bestored in database 530 for subsequent access, use, modification and/ordistribution. For example, database 530 may include a data storagesystem made up of one or more repositories that together storeinformation related to system 500. Database 530 may include one or morelocal databases, for example housed locally at the manufacturinglocation, and/or may include one or more remote databases.

In an exemplary embodiment, database 530 includes a cloud-based systemthat may be accessed remotely, and access to various components ofdatabase 530 selectively granted to particular users. A manufacturerand/or system administrator may have complete access to all aspects ofdatabase 530, while a remote party may be granted access only toparticular content, such as particular slab image files 520 the remoteparty has purchased or is considering purchasing, for example.

In some exemplary embodiments, all or portions of slab image file 520and/or metadata 525 are stored as read-only data. Such information maybe permanently associated with a particular stone slab 50 a. Forexample, a unique identifier, manufacturing time, dimensionalrelationship(s), and/or color characteristics may be stored as read-onlydata. Other information, such as a purchaser of stone slab 50 and/orother information may be readily updateable throughout the life of slabimage file 520, and may be selectable such that certain metadata may beincluded and/or viewable only by a particular user.

In addition to slab image files 520, database 530 may store other stoneslab information 532 and/or distribution information 533 related to oneor more remote parties. Such information may similarly be used for oneor more operations related to stone slabs 50 and/or selectivelydistributed to one or more users.

Still referring to FIG. 5, stone slabs, such as stone slab 50 a, and oneor more associated slab image files 520 may subsequently be distributedto a remote party 540. For example, in a distribution operation,particular stone slabs and associated slab image files 520 are assignedto remote party 540. Remote party 540 may be a distributor, fabricator,installer, purchaser of one or more stone slabs, or a prospectivepurchaser considering purchasing one or more stone slabs. In anexemplary embodiment, remote party 540 is a countertop fabricator thatdesigns, cuts, and/or installs countertops in an end-use application atone or more locations remote from a manufacturing location of stone slab50 a. In other exemplary embodiments, remote party 540 may be adistributor, end user, or other member of a distribution chain.

Distribution of slab image files 520 from a location of manufacturingline 510 thus allows remote party 540 to receive stone slabs 50 a andslab image files 520 independent of one another. One or more stone slabsmay be delivered to remote party 540 before, after or simultaneouslywith associated slab image files 520. For example, in an exemplarydistribution operation, slab image files 520 associated with stone slabsassigned to remote party 540 are provided to remote party 540 beforestone slabs 50 a are physically provided to the remote party 540. Remoteparty 540 may review and/or use slab image files 520 for distribution,modeling, cutting or other operations in a time period that is hours,days or weeks in advance of physically receiving, handling and/orstoring the stone slabs. In this way, remote party 540 may beginpreparatory operations for a particular installation, for example, atleast partly independent of stone slab 50 a, for example. Upon receiptby remote party 540, stone slab 50 a may be immediately cut and/orinstalled at a location of end-use based on plans created using slabimage file 520. Storage time and handling by remote party 540 may thusbe reduced, facilitating efficiency and reducing an inventory held byremote party 540.

Alternatively or in addition, slab image files 520 may be provided forreview by remote party 540 before associated stone slabs are shipped.Remote party 540 may review and confirm or terminate shipment based atleast in part, and/or solely, on slab image files 520. In this way,physical handling and other costs associated with denied or returnedshipments may be further reduced.

In some exemplary embodiments, one or more associated stone slabs andslab image files 520 may be provided together. For example, slab imagefiles 520 may be physically delivered on a storage device with stoneslabs 550. Slab image files 520 can immediately be used by the remoteparty in stone slab management, cutting, and/or other operations withoutfurther need to create an image or other catalog of the received stoneslabs at the remote party location. Cost and floor space otherwiserequired by an image generator station may thus be omitted and dedicatedto other stations of remote party 540.

In some exemplary embodiments, slab image files 520 stored in database530 may be accessed to communicate and/or display selected data fromimage file 520 without distributing an entire image file 520 itself. Forexample, server system 11 (FIG. 1) may access image files 520 andcommunicate an image and/or selected data from image file 520 to clientdevice 60 (FIG. 1). The client device 60 may in turn display the imageand/or selected data for viewing by a user. In some embodiments, animage transmitted to client device 60 may be compressed or have lowerresolution than an image stored in image file 520. A user may thusquickly view various images associated with an inventory of stone slabson client device 60 (e.g. remote from server system 11 and/or database530).

Referring to FIG. 6, a flow chart of an exemplary process 600 ofmanufacturing and managing an inventory of surfaces, such as stoneslabs, is shown. In some embodiments, the stone slabs may have featuressimilar to slabs 50 a, 50 b, 50 c, of the inventory of stone slabs 50described above. The stone slabs may be imaged before distribution fromthe manufacturing location, as described above with system 500, forexample, to generate an image file and metadata including informationabout an associated stone slab. Alternatively or additionally, the stoneslabs may be imaged at a location remote from the manufacturinglocation, such as at a location where one or more fabrication operationsare performed. Each of the stone slabs may include a quartz materialand/or other particulate mineral material that, when mixed with pigmentsand a resin binder and compressed, provides a hardened slab productsuitable for use in living or working spaces. In an exemplaryembodiment, stone slabs comprise predominantly quartz material.

Exemplary process 600 may include operation 602 of dispensing one ormore pigmented particulate mineral mixes into a mold to generate a slabhaving a desired aesthetic appearance. In some embodiments, one or moreof the particulate mineral mixes used to form the stone slabs caninclude organic polymer(s) and an inorganic (mineral) particulatecomponent. The inorganic (mineral) particulate component may includesuch components as silicon, basalt, glass, diamond, rocks, pebbles,shells, a variety of quartz containing materials, such as, for example,but not limited to: crushed quartz, sand, quartz particles, and thelike, or any combination thereof. In some embodiments, one or moreparticulate mineral mixes each comprise a quartz material as apredominant component, which may include sand of various particle sizesand of different combinations. In the resulting stone slab, the organicand inorganic materials can be linked using a binder, which may includefor example, mono-functional or multifunctional silane molecules,dendrimeric molecules, and the like, that may have the ability to bindthe organic and inorganic components of the composite stone mix. Thebinders may further include a mixture of various components, such asinitiators, hardeners, catalysators, binding molecules and bridges, orany combination thereof. Some or all of the mixes dispensed in the moldmay include components that are combined in a mixing apparatus (notshown) prior to being conveyed to the mold. The mixing apparatus can beused to blend raw material (such as the quartz material, organicpolymers, unsaturated polymers, and the like) at various ratios. Forexample, some or all of the mixes dispensed in the mold may includeabout 8-95% quartz aggregates to about 5-15% polymer resins. Inaddition, various additives, may be added to the raw materials in themixing apparatus, such additives may include, metallic pieces (e.g.,copper flecks or the like), colorants, dyes, pigments, chemicalreagents, antimicrobial substances, fungicidal agents, and the like, orany combination thereof.

After the mold has been sufficiently filled in operation 602, the moldmay be moved to one or more subsequent operations. For example,exemplary process 600 may include a vibro-compaction press operation 604during which compaction pressure, vibration, and vacuum may be appliedto the contents inside the filled mold, thereby converting the one ormore particulate mixes into a rigid slab. After vibro-compactionoperation 604, the filled mold (with the compacted and hardened slabtherein) may proceed to a curing operation 606 during which the materialused to form the slab (including any resin binder material) are curedvia a heating or other curing process, thereby further strengthening theslab inside the filled mold. After the slab is fully cured andsufficiently cooled, the hardened and cured slab may be removed from themold at a mold removal operation 608.

Process 600 may further include a polishing operation 610, during whicha major surface of the slab is polished to a smooth finish providing anappearance having, for example, complex striations and veining patterns.In such circumstances, the polished major surface of each of the moldedslabs provides an outer appearance that is generally repeatable andsimilar to the other slabs processed by process 600.

In an exemplary embodiment, process 600 includes an image generatoroperation 612 that can be used to generate an image associated with eachstone slab processed by process 600. Image generating operation 612 maybe performed after polishing operation 610 such that a polished slab canreadily proceed to image generator operation 612. In an exemplaryembodiment, image generating operation 612 generates a high resolution,medium format image associated with each stone slab. As described above,the resulting images may be stored as image files including associatedmetadata that may be used in inventory management, quality assurance,stone slab selection and matching, and fabrication operations, forexample, as described in greater detail herein.

Referring to FIG. 7, an exemplary stone slab 750 and associated slabimage file 720 are shown. Stone slab 750 may be a processed stone slab,quarried slab or other stone slab 750, and associated slab image file720 provides a high resolution image 721 and image metadata 725 relatedto stone slab 750. Stone slab 750 exhibits a variety of features andcharacteristics, for example resulting from a manufacturing process, andslab image file 720 may include a substantially distortion free, highresolution, medium format image 721 and image metadata related to suchfeatures and characteristics.

Similar to systems 10 and 500 described above, image metadata 725 mayinclude data related to stone slab 750 such as, for example, a uniqueidentifier associating slab image file 720 with a particular stone slab750, time and location of manufacture, dimensional information, weight,presence and/or location of imperfections, one or more colorcharacteristics, and/or other data.

In an exemplary embodiment, image metadata 725 includes a uniqueidentifier that allows association between a particular stone slab 750and an associated slab image file 720. The unique identifier may includea unique number, code or other identifier that uniquely identifies asingle stone slab 750 from one or more other stone slabs 750.

Stone slab 750 is tagged with the unique identifier and/or additionalinformation related to stone slab 750. In an exemplary embodiment, alabel 755 is provided on stone slab 750 that includes the uniqueidentifier in a computer-readable and/or human readable format. Thelabel may include a barcode, RFID tag, QR code, etching or writingdirectly on the stone slab, and/or other identifier. In some exemplaryembodiments, the label may be placed on the surface, edge, underside, orinside of the stone slab. In some exemplary embodiments, the label maybe an RFID tag that is embedded in the stone slab such that the tag isnot visually perceptible (e.g. when stone slab is installed) but maycommunicate the unique identifier and/or other information wheninteracted with by an appropriate reader, such as a scanner or RFID tagreader. Alternatively, the unique identifier may be printed on the stoneslab, for example on the back of the slab. The unique identifier may beused throughout the life of the associated stone slab to associate thestone slab with an image and/or other information related to stone slab750.

Still referring to FIG. 7, stone slab 750 and image 721 may exhibit adimensional relationship such that image 721 and/or metadata 725provides accurate information related to one or more dimensionalcharacteristics of stone slab 750. In an exemplary embodiment, stoneslab 750 exhibits various dimensions including a width W and Length Lresulting from a molding and/or cutting operation. Stone slab 750 mayalso have an aesthetic effect such as veins 751 and 752 that extendpartly or fully across a complete length L of stone slab 750 that may becharacterized by particular dimensions and spacing. For example, suchaesthetic effects may be positioned relative to one another based on apredetermined pattern, and may be similar among a set of stone slabs750.

Image 721 provides a dimensionally accurate representation of stone slab750 that both accurately represents relative positioning of edges, veinsand/or other features within the slab image, and allows accuratedetermination of absolute distances between edges and/or such features.Such dimensional accuracy allows image 721 to be used in slabvisualization models, selecting and matching operations, and in nestingoperations in which stone slab 750 is divided into portions havingdesired sizes and characteristics for a particular installation. Forexample, image 721 may be substantially distortion free such thatrelative positioning of various aesthetic features depicted by image 721is consistent with stone slab 750.

In an exemplary embodiment, one or more images 721 have a predetermineddimensional relationship with stone slabs 750, such as a consistentratio of stone slab unit length per image pixel. For example, one ormore images 721 may exhibit a ratio of stone slab unit length per imagepixel having a desired value. In various exemplary embodiments, a lengthratio (L_(slab)/L_(image)) of slab length (L_(slab)) to image length(L_(image)) may be less than 0.02 in. per pixel, less than 0.018 in. perpixel, less than 0.016 in. per pixel, less than 0.014 in. per pixel,less than 0.012 in. per pixel, or less than 0.01 in. per pixel. Forexample, a length ratio of (L_(slab)/L_(image)) may be between 0.005 in.per pixel to 0.02 in. per pixel, 0.01 in. per pixel to 0.018 in. perpixel, or about 0.014 in. per pixel. Such dimensional relationshipsprovide a known relationship (e.g. that can be identified by accessingthe metadata stored in the slab image file) and can facilitate a highdegree of precision in generating a scene in slab visualizationoperations, selecting and matching operations, and nesting operations,for example.

In an exemplary embodiment, image 721 is substantially distortion freesuch that the length ratio (L_(slab)/L_(image)) of unit slab length toimage length is substantially consistent at any location of image 721.For example, a particular length of image 721 corresponds to aconsistent length of stone slab 750, irrespective of whether the lengthis at a peripheral edge, middle, or other location of image 721. Image721 thus provides a reliable tool for measuring and cutting stone slab750. Nesting layouts in which veins, coloring and/or imperfections areintended to be included or avoided in a cut portion or seam, forexample, can be prepared using image 721 and reliably applied to stoneslab 750. Similarly, image 721 provides a reliable tool for generating a3D scene that provides a visualization of the associated stone slab inan installation environment. The positioning of veins, coloring and/orimperfections relative to other portions of the slab and/or installationenvironment can be accurately reproduced in the 3D scene. The 3D scenecan thus more accurately represent the visual appearance of the physicalstone slab installed in the installation environment.

Furthermore, such dimensional accuracy allows image 721 to be reusedthrough the life of any remaining portion of stone slab 750. Forexample, after stone slab 750 is cut to remove a portion having adesired size, dimensions of the removed portion and/or remaining slabmay be accurately depicted using image 721. Image 721 can thus be reusedin subsequent cutting or other operations without a need to generate anew image from the physical partial slab.

In an exemplary embodiment, image metadata 725 includes dimensionalinformation related to stone slab 750 described above. For example,image metadata 725 may include width, length, thickness and/or otherdimensions of stone slab 750, width, length, thickness and/or otherdimensions of image 721, and/or one or more further dimensionalrelationships between stone slab 750 and image 721, such as the lengthratio (L_(slab)/L_(image)) of slab length (L_(slab)) to image length(L_(image)). Image 721 and image metadata 725 including dimensionalinformation may thus be used together in one or more operations of stoneslab 750. A high degree of dimensional accuracy and a predetermineddimensional relationship between image 721 and stone slab 750 allowstone slab to be accurately mapped and cut. Visualization operations inwhich a 3D scene is created including one or more portions of a stoneslab in an installation environment may be performed with limited or nophysical reference to stone slab 750. Similarly, subsequent nestingand/or other operations may be performed with limited or no physicalreference to stone slab 750.

In various exemplary embodiments, image metadata 725 may include one ormore color characteristics related to a color of stone slab 750. Forexample, image metadata 725 may include a color characteristic includinga numeric value representative of one or more of color intensity,uniformity and/or tonality. A color characteristic including a numericvalue may be generated using a color measurement and analysis technique.In an exemplary embodiment, a numeric value is generated using L*a*b*values. For example, L*a*b* values may be generated for some or alllocations and/or pixels of slab image 721 to provide an indicator ofvarious color characteristics of stone slab 750, including veining,flow, movement, distribution of particulate material, etc. useful insubsequent operations related to stone slab 750.

In an exemplary embodiment, image metadata 725 may include a numericcolor characteristic based at least in part on color characteristicsassociated with one or more regions of slab image 721. For example, slabimage 721 may be divided into imaginary regions (such as an array/matrixof regions (a), (b), etc.), and numeric color values generated for eachregion. Image metadata 725 may thus include one or morelocation-specific color characteristics, in addition to one or morevalues representative of an overall color characteristic of stone slab750.

Alternatively or in addition, image metadata 725 may include one or morenumeric color characteristic values, such as a slab color rating,representative of an overall color characteristic of stone slab 750and/or a combination of local color characteristic values. For example,image metadata 725 may provide a numeric color rating that provides anoverall indicator of color and that may be compared to color ratingsassociated with other stone slabs 750. That is, an exemplary numericcolor rating may provide an indicator of how a particular stone slab 750appears as compared to other stone slabs 750 having a similar styleand/or predetermined pattern. Accordingly, a set of stone slabs 750 of aparticular style having similar color ratings may be characterized ashaving a similar visual color appearance, while stone slabs 750 of aparticular style having different color ratings may be characterized asexhibiting relatively different visual appearances. In this way, asingle numeric color characteristic value included as image metadata725, alone or in combination with one or more items of information ofslab image file 720, may be used to quickly qualify, group, match,and/or select a specific stone slabs 750.

In some embodiments, image metadata 725 may include one or more colorcharacteristic values that are unique to image 471 and/or associatedstone slab 750. That is, an exemplary color characteristic may result ina numeric value or array of values representative of color values at oneor more locations of stone slab 750 that provides a unique colorsignature. For example, a unique numeric value may result from compilingcolor characteristics at various locations of slab image 721 to provideboth color information useful in subsequent operations and a numericvalue that uniquely identifies stone slab 750 based on colorcharacteristics of that particular stone slab 750.

In various exemplary embodiments, image metadata 725 may includeadditional information related to an appearance of stone slab 750. Forexample, image metadata 725 may include one or more defect identifiersproviding a location and/or other information regarding one or moredefects. Alternatively or in addition, image metadata 725 may includeinformation related to surface properties of stone slab 750, such asinformation related to surface polish, scratches, gloss, etc. In someexemplary embodiments, image metadata 725 includes gloss values acrossstone slab 750 that may be used to determine appropriate seam placement.

Referring now to FIG. 8, a flow diagram of an exemplary process 800 formanufacturing and managing a stone slab is shown, including variousoperations performed in conjunction with a slab image file associatedwith the stone slab. In an exemplary embodiment, process 800 firstincludes operation 802 of manufacturing the stone slab, such as stoneslabs 50 described herein. Manufacturing the stone slab may includesteps of dispensing one or more particulate mineral mixes in a mold,vibrating and/or compacting the particulate mineral mixes, curing thecompacted mix, and/or polishing a major surface of the resulting stoneslab. Alternatively, the stone slab may be a quarried natural stone slabthat is cut and/or polished during operation 802.

Process 800 further includes operation 804 of assigning a uniqueidentifier associated with the stone slab. The unique identifier mayinclude a unique number, code or other identifier that uniquelyidentifies a single stone slab from one or more other stone slabs. Insome exemplary embodiments, operation 804 of assigning a uniqueidentifier may include tagging the stone slab with the uniqueidentifier, for example by affixing a label, barcode, tag, etching orwriting on the stone slab, or other technique.

In an exemplary embodiment, process 800 includes operation 806 ofgenerating a slab image file associated with the stone slab manufacturedin manufacturing operation 802. As described herein, operation 806 mayinclude generating a high resolution image, such as a high resolution“medium format” image, for example, of the stone slab and/or generatingimage metadata including information related to the stone slab andimage. In an exemplary embodiment, operation 806 of generating a slabimage file is performed at the same location, and in some embodiments,at the same manufacturing line, as operation 802 of manufacturing thestone slab. For example, a stone slab may proceed from a polishing lineto an image generator, as described above with reference to systems 100,500, such that less physical handling and other manipulation is requiredto position the stone slab for imaging.

Exemplary process 800 further includes operation 808 of storing a slabimage file in a database. For example, one or more slab image filesgenerated in operation 806 may be transferred to or otherwise stored ina database for subsequent access, use, modification and/or distribution.Operation 808 may include steps of storing the slab image file to acloud-based database system and/or grouping the slab image filesaccording to one or more features and characteristics stored as imagemetadata.

In various exemplary embodiments, operation 806 of generating a slabimage file results in an image and image metadata (e.g. uniqueidentifier, manufacturing location and/or date/time, dimensionalrelationship(s), thickness, gloss readings, color characteristics,purchaser information, processing conditions, genealogy, etc.)associated with a particular stone slab that can streamline and/orautomate various subsequent operations before stone slabs are deliveredto a remote party. For example, the slab image file may be used inoperation 810 of qualifying stone slabs produced during manufacturingoperation 802. Qualifying operation 810 may include confirming theabsence of defects and/or ensuring features and characteristics of astone slab are within a predetermined acceptable range using the slabimage file generated in operation 806. For example, one or more numericdimensional, color characteristic and/or other characteristics stored asimage metadata may be compared to a predetermined acceptablecharacteristic value or range of values, and the stone slab qualifiedand/or sorted for subsequent operations based on the one or more numericcharacteristics.

Operation 810 of qualifying a stone slab may further include grouping astone slab with one or more other stone slabs exhibiting similarfeatures and characteristics. For example, a stone slab having adimensional, color and/or other characteristic within a particular rangemay be assigned to a first group of stone slabs, and a stone slab havinga color characteristic value within a different range may be assigned toa second group of stone slabs. A slab image file storing the colorcharacteristic value thus allows grouping of stone slabs withoutextensive human review of either the physical stone slab or an image.Qualifying an inventory of stone slabs into one or more groups having asimilar characteristic facilitates efficient management and distributionof stone slabs, as described herein.

In some exemplary embodiments, operation 810 may include grouping one ormore stone slabs according to a pre-loaded algorithm. For example, afirst stone slab may be grouped as the closest match to a second stoneslab based on dimensional, color, and/or other characteristics (e.g.stored as image metadata). Accordingly, a second stone slab may beidentified as an alternative or back-up to a first stone slab in theevent the first stone slab is lost, damaged, assigned to a differentcustomer, etc. The second stone slab may be readily incorporated into avisualization and/or assigned for delivery to a particular customer(e.g. instead of the first stone slab). Alternatively or additionally,two or more stone slabs may be grouped as compatible for installationtogether in a single installation environment based on dimensional,color, and/or other characteristics. In some embodiments, gloss valuesstored as image metadata may be used to group two or more stone slabscompatible for seaming operations.

Exemplary process 800 may further include operation 812 of generating avisualization of a stone slab. Operation 812 may include generating ascene (e.g. a 2D scene, 3D scene, or other virtual reality environment)depicting at least a portion of a major surface of a stone slabassociated with the slab image file in a slab installation environment.Operation 812 may be performed at a server system and/or client device,for example, configured with software programmed to receive a slab imagestored in the database and/or an image of the slab installationenvironment, incorporate at least a portion of the stone slab image inthe slab installation environment to generate the scene, and transmitthe scene to a client device for display.

Process 814 may include operation 814 of generating a cost quote for thestone slab(s) to be delivered, fabricated, and/or installed. Operation814 of generating a cost quote may include analysis of one or moreselections related to the visualization of the installation environment.For example, navigation through a user interface may generate a finalinstallation configuration including a stone slab (e.g. associated witha physical stone slab in an inventory of stone slabs), dimensions of atarget area where the stone slab is to be installed, edge profile,and/or other characteristics that can be used to generate a reliable andaccurate cost quote. The server system and/or the client application ofa client device may be programmed with software that identifies a costassociated with each characteristic and/or combination ofcharacteristics of the installation environment. The costs may becomplied to generate a cost quote in real-time that is displayed by theclient interface while the scene is generated and/or modified.Alternatively or additionally, a cost quote may be generated after aninput is received that confirms the final installation configuration.

Still referring to FIG. 8, process 800 includes operation 816 ofassigning one or more stone slabs to a remote party. For example, one ormore stone slabs may be assigned as part of a purchasing process. Aftera user views a visualization generated in operation 812, the associatedstone slab may be selected for purchase and assigned to the user.Alternatively or additionally stone slabs may be assigned in preparationof delivery and/or in response to an order placement or other requestfrom a remote party. In an exemplary embodiment, stone slabs areassigned to a remote party at least in part using image metadata of aslab image file. For example, a set of stone slabs may be assigned tothe remote party from a set of stone slabs previously grouped based onone or more characteristics stored as image metadata. In someembodiments, the slab image file may be used to identify a stone slabhaving a similar dimensional, color and/or other characteristic inresponse to a request for a particular style. Stone slabs having one ormore similar characteristics may thus be identified and assigned withlittle or no human review of the stone slab or image based at least inpart on an image and/or metadata generated at the location ofmanufacturing operation 802.

At operations 818 and 820, slab image files and/or associated stoneslabs may be provided to a remote party. Slab image files and stoneslabs may be provided to the remote party in any sequence. In anexemplary embodiment, one or more slab image files are provided to aremote party in advance of delivery of associated stone slabs.Accordingly, the remote party may review and/or use the slab image fileswhile the physical stone slab remains in a remote location. Further, theslab image file may allow the remote party to confirm or canceldelivery, begin preparing layouts in a nesting operation, and/or makeother decisions regarding associated stone slabs before stone slabs haveleft a manufacturing or storage facility. Alternatively, or in addition,slab image files and stone slabs may be provided to the remote partysubstantially simultaneously. When received by the remote party, afabrication operation, for example, may be initiated immediately byusing the associated slab image files, while additional processing stepsof inspecting, cataloging, and/or imaging the received stone slabs atthe remote party location are reduced.

In some exemplary embodiments, the slab image file is not provided to aremote customer. Layouts for a nesting operation generated duringvisualization operation 812 may be used to map cuts of the associatedphysical stone slab, and an additional nesting operation (e.g. using theslab image file) may be omitted.

Operation 818 of providing slab image files to a remote party mayinclude one or more steps of making slab image files available to aremote party. In an exemplary embodiment, providing slab image files toa remote party includes assigning an identifier, such as a customeridentifier, lot identifier, order identifier, etc. to one or more slabimage files associated with stone slabs to be provided to the remoteparty. Slab image files associated with the identifier may then bestored in a database or other repository accessible by the remote partyto view, download, use and/or otherwise access such slab image files. Inthis embodiment, slab image files are accessible by a particular remoteparty, and are not accessible by other remote parties to which the stoneslabs are not assigned. Slab image files of the actual stone slabs,rather than merely representative images, are thus made available to theremote party. Alternatively or in addition, associated slab image filesmay be directly transferred to the remote party, for example byelectronic distribution and/or physical delivery of a storage mediumcontaining the one or more slab image files.

Referring to FIG. 9, a flow diagram of an exemplary process 900 ofgenerating a visualization of a stone slab in an installationenvironment is shown. Process 900 may be performed partially or entirelyby a server system (e.g. server system 11) configured to communicatewith a client device (e.g. client device 60). The server system maygenerate all or particular components of a scene, and transmit thegenerated components or scene to the client device for display.

Process 900 includes operation 902 of receiving by a server system anenvironment image of a slab installation environment. The environmentimage may be an image of a kitchen, bathroom, work area, etc. thatincludes an area where a stone slab can be installed (e.g., along acountertop, table, floor, or the like). The server system may receivethe environment image from the client device, production database, orother repository. In an exemplary embodiment, the environment imagedepicts an end-use location where a stone slab is to be installed. Inother exemplary embodiments, the environment image depicts anenvironment that has characteristics representative of the type ofenvironment where the physical stone slab may be installed (e.g. akitchen environment, a bathroom environment, a workspace environment).For example, the environment image may be a pre-loaded environment imagehaving characteristics of the type of environment where the physicalstone slab may be installed and/or may be reused by multiple users.

The environment image may include a photo, infrared image,three-dimensional scan, or computer-aided drawing, for example. In someembodiments, the environment image is generated from a three-dimensionalscan including visible and infrared imaging. The three-dimensional scanmay be analyzed to extract dimensional information related to theinstallation environment. In some exemplary embodiments, the clientdevice may include a visible light camera, infrared camera 3D scanningdevice, time-of-flight camera, structured light scanner, stereoscopicscanner, or other image capture device configured to capture anenvironment image, and/or a communication device configured to transmitthe environment image to server system 11.

Process 900 includes operation 904 of determining a geometry of a targetarea of the slab installation environment where a stone slab may beinstalled. Operation 904 may include determining a location of thetarget area (e.g. relative to other components of the slab installationenvironment outside of the target area), and determining absolutedimensions of the target area. In an exemplary embodiment, the serversystem may be programmed to identify a target area by recognizingfeatures of the slab installation environment, such as existingcountertops. The target area may thus be at least partially defined byan area occupied by existing countertops.

In the server system may be programmed to autonomously determinedimensions of the target area, such as by using photogrammetrytechniques. In some embodiments, the environment image received by theserver system may include dimensional data from which the geometry ofthe target area may be readily calculated. Alternatively oradditionally, a target area may be manually selected using a userinterface in communication with the server system, such as by manuallyselecting a feature of the environment image (e.g. such as existingcountertops), drawing a box around a target area, or otherwise manuallydesignating an area of the environment image as a target area.Dimensions of the selected target area may then be extracted by theserver system.

Process 900 further includes operation 906 of receiving a slab imagefile. In an exemplary embodiment, slab image file may be similar to slabimage files 20, 520, 720, described above, and include an image of aphysical stone slab stored in an inventory of stone slabs and imagemetadata associated with the stone slab. The server system may receivethe stone slab image file from a production database (e.g. productiondatabase 30), client device (e.g. client device 60), or anotherrepository of slab image files. In an exemplary embodiment, operation906 may include identifying a slab image file based on characteristicsstored as metadata in the slab image file (e.g. based on a particularslab style, manufacture date, dimensions, color characteristics,movement, edge profile, gloss, or other characteristics). The desiredcharacteristics may be selected manually and/or according topreprogrammed instructions. For example, the system may receive inputfrom a user including a requested slab characteristic, and subsequentlyidentify slab image files having the requested characteristics.Alternatively or additionally, the system may identify slab image filescompatible with the target area identified in the environment imageaccording to preprogrammed instructions. For example, a slab image filemay be selected based on particular color characteristics that arecompatible with color characteristics of the environment image.Similarly, a slab image file may be selected based on the dimensions ofthe target area. A slab image file may be selected such that the numberof cuts required to fabricate countertops that fit the target area isreduced, or to match a previously cut slab with a target area havingsimilar dimensions to reduce waste. In various embodiments, a slab imagefile may be requested by the server system, and/or may be transmitted tothe server system based on instructions originating from a clientdevice.

In various exemplary embodiments, multiple slab image files may beselected for possible use in a subsequent visualization operation. Forexample, multiple slab image files associated with slabs having similarvisual appearances may be selected (e.g. based on user input and/oraccording to a pre-loaded algorithm). A first slab image file may be aprimary image file for visualization in an installation environment, anda second slab image file may be a secondary image file for visualizationin an installation environment. The primary and second image files maythus provide alternative image files that may be selected (e.g. based onthe generated visualization). Alternatively or in addition, thesecondary image file may provide a back-up in the event the stone slabassociated with the primary image file becomes lost or damaged.

In an exemplary embodiment, process 900 may include operation 908 ofgenerating a scene depicting at least a portion of the major surface ofthe stone slab associated with the slab image file at the target area inthe slab installation environment. Operation 908 may include executingrendering software programmed to combine at least a portion of the stoneslab image (e.g. depicting a major face of the stone slab) with the slabinstallation environment. In this way, a generated scene can provide auser with a realistic visualization of a particular stone slab in aninstallation environment. In some embodiments, the generated scene canprovide an accurate indication of the visual appearance of a stone slabwhen installed, while reducing physical manipulation and difficulty thatmay be associated with viewing the physical stone slab itself. Further,in embodiments in which the scene is generated using a slab image fileassociated with a physical stone slab and an environment image of theintended slab installation environment (e.g. a customer's kitchen,bathroom, workplace, etc.), the visualization may help a customer byproviding a preview (i.e., before purchasing and/or installing the stoneslab) of the visual appearance of the physical stone slab installed inthe user environment.

In many embodiments, operation 908 includes dividing the slab image intosmaller slab image portions having dimensions that match the target areaof the slab installation environment. For example, the server system mayinclude software programmed to divide the stone slab image into portionshaving dimensions based on the target area. A substantially distortionfree, high resolution image and dimensional characteristics stored asimage file metadata may promote reliability and accuracy in dividing theslab image into portions that precisely fit the target area.Furthermore, the operation of dividing the slab image into smallerportions to match the target area can be useful in subsequentfabrication operations. For example, the identified geometry of slabimage portions (e.g. relative to the overall dimensions of the slabimage) can be used during a subsequent fabrication operation to reliablyand accurately map and cut the associated physical stone slab. Operation908 may thus generate a slab layout that is dimensionally accurate suchthat the slab layout is useful both in slab visualization operations andin subsequent fabrication operations of the physical stone slab.

Operation 908 may include generating visible edges of the slab(s)installed in the installation environment. In scenarios in which theslab image must be divided to generate image portions that havedimensions based on dimensions of the target area, edges can be renderedso that the thickness of the slab is visible and accurately depictsvisual features extending through the thickness.

Operation 910 includes transferring the scene to a client applicationfor display of the scene by a client device. For example, the scene maybe transferred to the client application via a network communicationdevice. In various exemplary embodiments, the scene may be completely orpartially generated at the server system such that processing burden onthe client device is reduced. In some embodiments, the scene may includeseveral components that can be assembled or otherwise utilized by theclient application to display the generated scene.

Referring to FIG. 10, a flow diagram of an exemplary process 908 ofgenerating a visualization of a stone slab in an installationenvironment is shown. Process 908 may be performed partially or entirelyby a server system (e.g. server system 11) configured to communicatewith a client device (e.g. client device 60). The server system maygenerate all or particular components of a scene, and transmit thegenerated components or scene to the client device for display.Alternatively or additionally, process 908 may be performed partially orentirely by a client device.

Process 908 includes operation 908 a of identifying a slab image filefor use in a slab visualization. In some embodiments, operation 908 amay be similar to the operation of identifying a slab image filedescribed above with reference to operation 906. Operation 908 a mayinclude identifying a slab image file based on characteristics of theassociated stone slab, such as characteristics stored as metadata in theslab image file. For example, an image file may be identified bysearching the database of slab image files using image file metadatabased on criteria of a particular slab style, dimensions, colorcharacteristics, movement, edge profile, gloss, and/or othercharacteristics.

Operation 908 a may include receiving manual input from a user ofselected characteristics. For example, a user may select a desired slabstyle from a menu of available slab styles. The server system may beconfigured with software programmed to receive the user input andidentify slab image files associated with the selected slab style fromthe database. Alternatively or additionally, a user may select a desiredslab dimension, color characteristics, movement, edge profile, gloss,and/or other characteristics.

Operation 908 a may be at least partially automated. In someembodiments, the server system may be configured with softwareprogrammed to identify a particular slab image file based partially onmanual input received from a client device and partially accordingly topreprogrammed instructions. For example, the server system may identifya particular stone slab image file from a group of slab image filesidentified based on the characteristics received from the client device.In one embodiment, a particular stone slab image file may be selectedbased on a manufacture date, color characteristics, movement, edgeprofile, gloss, or other characteristics. In other embodiments, thefirst slab image file identified as having the characteristics input bythe user may be selected for use.

In some embodiments, operation 908 a may include identifying a slabimage file compatible with a target area identified in the environmentimage. A slab image file may be selected based on particular colorcharacteristics that are compatible with color characteristics of theenvironment image. Similarly, a slab image file may be selected based ondimensions of the target area. For example, a slab image file may beselected based on dimensions of the target area so as to reduce thenumber of cuts required to fabricate countertops that fit the targetarea, or so that a previously cut slab may be used, reducing wastedmaterial (e.g. a small slab may be selected for use with a small targetarea, thus identifying a slab for installation that may have otherwisebeen discarded).

In some embodiments, operation 908 a includes identifying a slab imagefile at least partially based on preprogrammed instructions in a mannerthat reduces the processing burden of the system. For example, theserver system may include software programmed to compare variouscharacteristics stored in the image file metadata according to apredetermined sequence. In one embodiment, slab image files having aparticular style are first identified, followed by one or more of aparticular dimension, color characteristics, etc.

In an exemplary embodiment, process 908 includes operation 908 b ofdividing the slab image into image portions compatible with the targetarea of the slab installation environment. The slab image of the slabimage file (and the associated physical stone slab) have dimensions thatmay differ from dimensions of the target area of the slab installationenvironment. For example, the slab may have a rectangular shape withstandard dimensions, such as a length of 12 feet and a width of 4.5feet, or may have relatively smaller dimensions in scenarios in whichthe slab is a portion of a slab (e.g. that has been previously cut). Theserver system may include software programmed to divide the stone slabimage to generate portions having dimensions based on the target area. Asubstantially distortion free, high resolution image, and dimensionalcharacteristics stored as image file metadata, promote reliability andaccuracy in dividing the slab image into portions that precisely fit thetarget area, and that accurately represent cuts that can be made to thephysical stone slab during subsequent fabrication operations.

Operation 908 b may include generating slab image portions according toan algorithm or set of rules that produces an aesthetically pleasingconfiguration of the slab portions in the target area of the slabinstallation environment, while reducing processing power required tocomplete the operation. For example, the slab image may be divided basedon the presence and locations of aesthetic characteristics, such asveins, surface defects, gloss levels of the major surface, colormovement, etc. The slab image portions may be oriented so that veinsextend in an aesthetically pleasing direction, such as parallel orperpendicular to a direction of the longest dimension of the targetarea. In some embodiments, the slab image may be divided based on glossvalues stored for locations across the major face of the slab. Forexample, the slab image can be divided so that gloss values are similarat locations adjacent to seams (e.g. between slab image portions whenthe slab image portions are inserted at the target area of theenvironment image). Alternatively or additionally, the slab image may bedivided based on a preprogrammed algorithm configured to reduce thenumber of cuts that would be required to similarly divide the associatedphysical stone slab, and/or to reduce waste by maximizing the size ofleftover portions that are not applied to the target area of the slabinstallation environment.

In some exemplary embodiments, operation 908 b may generate slab imageportions according to user input associated with an orientation orpositioning of the slab. For example, a user may select a particularorientation of a stone slab relative to the target area (e.g. such thata vein or other feature has a selected orientation relative to theinstallation environment). Alternatively or additionally, a user mayselect a particular positioning of the stone slab relative to a targetarea (e.g. such that a vein or other feature has a selected positioningrelative to the installation environment). In some embodiments, a usermay input by dragging a simulated stone slab image into a desiredpositioning on a target area. Operation 908 b may divide the slab imageto generate slab image portions matched to the target area in theselected orientation and/or positioning.

Operation 908 b of dividing the slab image into smaller portions tomatch the target area of the slab installation environment can be usefulin subsequent fabrication operations. For example, the dimensions andlocations of the slab image portions (e.g. relative to the overalldimensions of the slab image) can be reused during a subsequentfabrication operation to reliably and accurately cut the associatedphysical stone slab. Operation 908 may thus generate a slab layout thatis useful both in generating the scene for visualization and insubsequent fabrication of the physical stone slab.

Process 908 may include operation 908 c of rendering edges of the slabimage portions. In scenarios in which the slab image must be divided togenerate image portions that match the target area, the slab image filemay not include an image of edges of the slab because the physical stoneslab has not yet been cut. In an exemplary embodiment, edges arerendered to accurately depict an aesthetic appearance of the thicknessof the stone slab. Veins visible on the major surface may be rendered asextending through the entire thickness of the slab image portion, andedges may be rendered with a predetermined profile, which may beselected by a user, for example. In some exemplary embodiments, serversystem may render a single edge profile that can be subsequentlymodified (e.g. via a client application). Alternatively or additionally,server system may render a plurality of slab image portion/edge profilecombinations that a user can subsequently select from or toggle between(e.g. via a client application). Alternatively, the server system mayrender an edge profile for each design.

Operation 908 b further includes combining the slab image portion(s)with the environment image to generate a scene (e.g. a 3D scene)depicting at least a portion of a major surface of the stone slabassociated with the slab image file at the target areas in the slabinstallation environment. In some embodiments, operation 908 b, resultsin a scene that depicts at least portions of a stone slab that isavailable in an inventory of stone slabs, and provides a reliable andaccurate installation visualization. In this way, a scene generatedaccording to some exemplary embodiments described herein provides notonly an accurate visualization of a particular style of stone slab in aninstallation environment, but can also provide an accurate visualizationof a specific stone slab. The aesthetic characteristics of the specificstone slab, such as the positioning of veins or other visual appearances(e.g. that may vary slightly even between slabs having the same style),are accurately depicted in the installation environment, and may beadjusted by the user.

In an exemplary embodiment, the slab image portions are combined withthe environment image such that at least the major surfaces of the slabimage portions are depicted in a non-repeating and non-tiling manner.For example, no portion of the major surface from the slab image isrepeated or distorted in the generated scene. The slab image portionsdepicted in the scene thus represent a configuration of physical stoneslabs that could be applied to target areas in the physical installationenvironment. The slab image portions may thus have dimensions and edgesthat accurately reflect dimensions and edges that could result fromphysically cutting and finishing the associated physical stone slab.

Referring now to FIG. 11, an environment image 1175 of a slabinstallation environment 1170 is shown. Slab installation environment1170 is a kitchen including one or more target areas 1171 where worksurfaces or countertops may be present or may be subsequently installed.Installation environment 1170 includes multiple target areas, 1171 a,1171 b, 1171 c, 1171 d. For example, target area 1171 a may be an areaof a kitchen island countertop, and target areas 1171 b, 1171 c may becountertops associated with cabinetry and/or positioned adjacent tovertical walls of slab installation environment 1170.

Target areas 1171 may have any selected orientation includinghorizontal, vertical, and/or slanted surfaces. In some exemplaryembodiments, target area 1171 includes vertically oriented target areas1171 d. For example, target area 1171 d may designate a surface thatprovides a “waterfall effect” and/or may extend between a floor andtarget area 1171 a.

An exemplary post-production system, such as post-production system 10,includes software programmed to identify target areas of environmentimage 1175 where a stone slab may be installed. System may includesoftware programmed to recognize features of the slab installationenvironment associated with a target area. In an exemplary embodiment,system 10 is programmed to recognize and identify target areas 1171 a,1171 b, 1171 c, 1171 d where a stone slab may be installed based on thepresence of existing countertops, the shape and/or configuration ofcabinetry 1172, or other characteristics of environment image 1170.Alternatively or additionally, target areas 1171 a, 1171 b, 1171 c, 1171d of the environment image 1170 may be manually identified via manualuser input at client device 60 (e.g. while client device displaysenvironment image 1170), such as by manually selecting an area ofenvironment image 1170, drawing a box around an area, or otherwisemanually designating an area of environment image 1170 as a target area.In an exemplary embodiment, system 10 identifies proposed target areas1171 a, 1171 b, 1171 c, 1171 d displays the proposed target areas 1171a, 1171 b, 1171 c, 1171 d to a user via a client device (e.g. bydesignating an area on broken lines, ghosting, etc.), and receives inputfrom a user confirming or canceling selection of one or more of targetareas 1171 a, 1171 b, 1171 c, 1171 d.

System 10 further includes software programmed to determine a geometryof the selected target areas 1171 a, 1171 b, 1171 c. For example, system10 is configured with software to determine a location of the targetareas 1171 a, 1171 b, 1171 c relative to other components of theinstallation environment, and to determine absolute dimensions of thetarget areas 1171 a, 1171 b, 1171 c. In some embodiments, theenvironment image 1170 may include dimensional data from which thegeometry of the target area may be calculated when received by system10. Alternatively or additionally, absolute dimensions may be determinedusing photogrammetry techniques, for example.

Referring to FIG. 12, a plan view of major surfaces of an exemplary slabimage 1221 divided into slab image portions 1221 a, 1221 b, 1221 c isshown. System 10 includes software programmed to divide the slab image1221 into slab image portions 1221 a, 1221 b, 1221 c having dimensionsthat correspond to the dimensions of target areas 1171 a, 1171 b, 1171 c(FIG. 11). In this way, slab image 1221 can be divided into imageportions that can be visualized in the target areas while maintainingdimensional accuracy and without repeating or tiling portions of slabimage 1221.

System 10 may include software programmed to divide slab image 1221 intoslab image portions 1221 a, 1221 b, 1221 c in a manner that produces anaesthetically pleasing configuration of the slab images portions 1221 a,1221 b, 1221 c, in target areas 1171 a, 1171 b, 1171 c of theinstallation environment, while reducing processing power required tocomplete the operation. For example, slab image 1221 may be dividedbased on the presence and locations of aesthetic characteristics, suchas veins, surface defects, gloss levels of the major surface, colormovement, etc. Slab image portions may be oriented so that veins extendin an aesthetically pleasing direction, such as parallel orperpendicular to a longitudinal direction of the cabinetry, for example.In some embodiments, slab image 1221 may be divided based on glossvalues stored for locations across the major face of the slab. Forexample, slab image 1221 may be divided so that gloss values areconsistent adjacent to seams between slab image portions when the slabimage portions are inserted at the target area of the environment image.Alternatively or additionally, slab image 1221 may be divided based on apreprogrammed algorithm configured to reduce the number of cuts thatwould be required to similarly divide the associated physical stoneslab, and/or to reduce waste by maximizing the size of leftover portions(not shown in FIG. 12) that are not applied to the target area of theslab installation environment. In some embodiments, the target area mayhave the same geometry as the major surface of the stone slab (e.g. andslab image 1221) such that slab image 1221 can be applied to the targetarea without dividing into slab image portions. Alternatively, thetarget area may have the same geometry as the major surface of the stoneslab

In an exemplary embodiment, system 10 may be configured to update animage file including slab image 1221 to include dimensional informationrelated to image portions 1221 a, 1221 b, 1221 c. The dimensions andlocations of the slab image portions (e.g. relative to the overalldimensions of the slab image) can be used during a subsequentfabrication operation to reliably and accurately cut the associatedphysical stone slab.

While this specification contains many specific implementation details,these should not be construed as limitations on the scope of anytechnology described herein or of what may be claimed, but rather asdescriptions of features that may be specific to particular embodiments.Certain features that are described in this specification in the contextof separate embodiments can also be implemented in combination in asingle embodiment in part or in whole. Conversely, various features thatare described in the context of a single embodiment can also beimplemented in multiple embodiments separately or in any subcombination.Moreover, although features may be described herein as acting in certaincombinations and/or initially claimed as such, one or more features froma claimed combination can in some cases be excised separate from thecombination, and the claimed combination may be directed to asubcombination or variation of a subcombination.

Similarly, while operations are depicted in the drawings in a particularorder, this should not be understood as requiring that such operationsbe performed in the particular order shown or in sequential order, orthat all illustrated operations be performed, to achieve desirableresults. Although a number of implementations have been described indetail above, other modifications are possible. For example, the logicflows depicted in the figures do not require the particular order shown,or sequential order, to achieve desirable results. In addition, othersteps may be provided, or steps may be eliminated, from the describedflows, and other components may be added to, or removed from, thedescribed systems. Accordingly, other implementations are within thescope of the following claims.

1.-20. (canceled)
 21. A system for producing stone slabs, comprising: aproduction database stored at a server system and including slab imagefiles associated with a physical inventory of stone slabs, each slabimage file associated with only a single stone slab in the physicalinventory of stone slabs and including: an image of a major surface ofthe single stone slab, and image metadata including an identifier thatuniquely identifies the single stone slab, and one or morecharacteristics of the single stone slab; the server system includingsoftware programmed to identify a first slab image file from theproduction database that is similar to a second slab image file from theproduction database based on the one or more characteristics.
 22. Thesystem of claim 21, wherein the one or more characteristics include acolor characteristic, and the software is programmed to identify thefirst slab image file and the second slab image file based on the colorcharacteristic.
 23. The system of claim 22, wherein the colorcharacteristic includes a numeric value that represents an overall colorcharacteristic of the associated stone slab.
 24. The system of claim 22,wherein the color characteristic includes a color intensity value, coloruniformity value, or color tonality value.
 25. The system of claim 22,wherein the color characteristic includes a veining characteristic. 26.The system of claim 22, wherein the color characteristic includes a flowcharacteristic.
 27. The system of claim 22, wherein the colorcharacteristic includes a location-specific color characteristic. 28.The system of claim 21, wherein the characteristic includes a glossvalue.
 29. The system of claim 21, wherein the image of the majorsurface of the single stone slab has an image length and an image width,the single stone slab has a stone slab length and a stone slab width,and the characteristic includes a numeric ratio of the stone slab lengthto the image length (L_(slab)/L_(image)).
 30. The system of claim 21,wherein the one or more characteristics include: a first numeric valuecorresponding to a first visual quality of the single stone slab, and asecond numeric value corresponding to a second visual quality of thesingle stone slab.
 31. The system of claim 22, wherein the server systemincludes software programmed to receive the first and second slab imagefiles from the production database and an environment image of a slabinstallation environment, and generate a 3D scene depicting at least aportion of major surfaces of first and second stone slabs associatedwith the first and second slab image files in the slab installationenvironment.
 32. The system of claim 31, wherein the server system isfurther programmed to determine a geometry of a target area of the slabinstallation environment where the first and second stone slabs are tobe installed, and wherein the target area has a different geometry thanthe major surfaces of the first and second stone slabs.
 33. The systemof claim 22, wherein the inventory of stone slabs comprises processedstone slabs.
 34. The system of claim 22, wherein the inventory of stoneslabs comprises quarried stone slabs.
 35. A method for producing stoneslabs, comprising: storing slab image files at a production database ofa server system, the slab image files associated with a physicalinventory of stone slabs, each slab image file associated with only asingle stone slab in the physical inventory of stone slabs, each slabimage file including: an image of a major surface of the single stoneslab, and image metadata including an identifier that uniquelyidentifies the single stone slab and one or more characteristics of thesingle stone slab, the one or more characteristics including a colorcharacteristic; and identifying a first slab image file from theproduction database and a second slab image file from the productiondatabase based on a similarity of color characteristics of the first andsecond slab image files.
 36. The system of claim 35, wherein the one ormore characteristics include: a first numeric value corresponding to afirst visual quality of the single stone slab, and a second numericvalue corresponding to a second visual quality of the single stone slab.37. The method of claim 36, wherein the color characteristics includes anumeric value that represents an overall color characteristic of theassociated stone slab.
 38. The method of claim 37, wherein the colorcharacteristics includes a gloss value and a location associated withthe gloss value.
 39. The method of claim 38, further comprising:determining a location for a seam based on the color characteristics.40. A system for producing stone slabs, comprising: means for generatingslab image files associated with a physical inventory of stone slabs,each slab image file associated with only a single stone slab in thephysical inventory of stone slabs, each slab image file including: animage of a major surface of the single stone slab, and image metadataincluding an identifier that uniquely identifies the single stone slaband one or more characteristics of the single stone slab, the one ormore characteristics including a color characteristic; and means forstoring the slab image files, the slab image files configured to bematched based on a similarity of color characteristics.